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Home › Chevrolet › 2004 › Astro Van Cargo, AWD › Repair and Diagnosis › Suspension › Front Suspension › Front Suspension System › Repair Instructions › Lower Control Arm Replacement (AWD) › Installation Procedure

Installation Procedure

  1. Install the lower control arm brace to the lower control arm.
    IMPORTANT: Install the front leg of the lower control arm to the crossmember before installing the rear leg to the frame bracket.
  2. Install the lower control arm to the crossmember and frame bracket.
  3. Install the lower control arm bolts in the proper direction.
    Fig 1: View Of Lower Control Arm Mounting Bolts, Nuts & Washer
    GM178925Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: Tighten the nuts with the control arm at Z height. Refer to Trim Height Inspection Procedure in Suspension General Diagnosis.
  4. Install the new nuts and the washers.

    Tighten: 

    1. Tighten the lower control arm nuts and bolts with the front suspension loaded.
    2. Tighten the lower control arm front mounting nuts to 133 N.m (98 lb ft).
    3. Tighten the lower control arm rear mounting nuts to 133 N.m (98 lb ft).

  5. Install the steering knuckle and the wheel hub and bearing to the lower ball joint.
  6. Install the lower ball joint retaining nut.
    Fig 2: Locating Upper Ball Joint Retaining Nut & Cotter Pin
    GM689207Courtesy of GENERAL MOTORS CORP.
  7. Connect the upper ball joint to the steering knuckle.
  8. Install the upper ball joint retaining nut.

    Tighten: 

    • Tighten the upper ball joint retaining nut to 98 N.m (72 lb ft).
    • Tighten the lower ball joint retaining nut to 128 N.m (95 lb ft).

  9. Install new cotter pins to the upper and lower ball joints. Tighten the nut up to an additional amount in order to insert the cotter pin through the upper and lower ball joint studs. Bend the cotter pin ends flat against the nut.
  10. Connect the wheel speed sensor wiring harness clips to the upper control arm.
  11. Install the wheel speed sensor wiring harness bracket retaining bolts at the steering knuckle and the frame.
  12. Connect the wheel speed sensor electrical connector.
  13. Connect the outer tie rod to the steering knuckle.
  14. Install the outer tie rod retaining nut and cotter pin.

    Tighten:  Tighten the outer tie rod retaining nut to 49 N.m (36 lb ft).

    Fig 3: Identifying Outer Tie Rod To Steering Knuckle Retaining Nut
    GM689102Courtesy of GENERAL MOTORS CORP.
  15. Install the wheel drive shaft washer and the retaining nut to the wheel hub and bearing.

    Tighten:  Tighten the wheel drive shaft retaining nut to 235 N.m (173 lb ft).

    Fig 4: View Of Wheel Drive Shaft Retaining Nut
    GM130905Courtesy of GENERAL MOTORS CORP.
  16. Install the rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes.
  17. Install the shock absorber lower mounting bolt.

    Tighten:  Tighten the lower shock mounting bolt to 62 N.m (42 lb ft).

    Fig 5: Identifying Shock Absorber Lower Mounting Bolt
    GM165007Courtesy of GENERAL MOTORS CORP.
  18. Install the stabilizer shaft link. Refer to Stabilizer Shaft Link Replacement (RWD)  or Stabilizer Shaft Link Replacement (AWD) .
  19. Install the torsion bar. Refer to Torsion Bar Replacement .
  20. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  21. Lower the vehicle.
  22. Check the front wheel alignment. Refer to Measuring Wheel Alignment in Wheel Alignment.
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